Method and apparatus for pre-fabricating a synthetic sports field

Abstract

A method of prefabricating and installing a synthetic turf field includes providing a controlled manufacturing facility with an open area that allows a plurality of turf strips to be laid out on a floor thereof. Visual markings are placed on the floor to allow the individual strips to be properly aligned on the floor. Once aligned, inlays can be placed into the proper strip and then secured. After the inlays have been secured, the strips can be rolled up and appropriately labeled for subsequent installation. After all the strips that will make up the field have been processed and rolled up, the rolls can be taken to the job site so the field can be installed.

The invention claimed is: 
     
       1. A method of prefabricating a synthetic sports field in a separate controlled facility for subsequent installation, comprising:
 providing a plurality of unprocessed strips of synthetic turf; 
 visually marking lines on a substantially flat floor of the facility that corresponds to certain dimensions of the field, including a centerline; 
 laying out a plurality of said unprocessed strips on said floor back side up; 
 aligning each of said plurality of said unprocessed strips with respect to said centerline; 
 marking said centerline onto said back side of each of said unprocessed strips; 
 inlaying any necessary markings into each strip; 
 rolling up each of said strips; 
 transporting said rolls to an installation site; and 
 installing said strips to form the synthetic field. 
 
     
     
       2. The method of  claim 1 , wherein said step of inlaying includes cutting an opening in said strip that matches said marking to be inserted into said strip; and
 securing said marking in said opening to said strip. 
 
     
     
       3. The method of  claim 2 , wherein said markings are selected from the group consisting of: hash marks, yard line numbers, or arrows. 
     
     
       4. The method of  claim 1 , wherein said visible markings on said floor also correspond to a first set of hash marks, a plurality of yard line numbers, a second set of hash marks, and side lines. 
     
     
       5. The method of  claim 4 , further comprising:
 cutting edges of said strip to match said sidelines, such that said strip is of the appropriate length.